
LIBRARY OF CONGRESS. 

' *%%£* 

Chap....}.„. Copyright No. 



Shelf. 



>JjL 



UNITED STATES OF AMERICA. 




DRAWING UP BOILER SHELLS. 



A PRESS OF THE FUTURE. 



DIES 



AND 



DIE MAKING. 



BY 

J. L. LUCAS. 



FIRST EDITION. 



1897 



1S\> 



Copyright, 1897, 

BY 

J. L. Lucas. 



g~^1f 



Printed by Journal of Commerce Co., Providence, R. 



TO 

ELISHA T. JENKS, 

WHOSE EARNEST EFFORTS TO INSTIL A FEW MECHANICAL IDEAS 

INTO THE BRAIN <»F THE AUTHOR WERE MET WITH 

BUT INDIFFERENT SUCCESS, THIS BOOK 

IS RESPECTFULLY DEDICATED. 



PREFACE. 

In putting this work before the public, the author is well 
aware that it will meet with criticism from those who are better 
informed on the subject than he; but a careful search in the 
bookstores and through the catalogues of the largest publishing 
firms failing to show a work of this kind, has led him to take up 
the task; and, although better fitted by experience for the file 
than the pen, lias done the best that he could. It is essentially 
a shop book, written by a shopman, and intended for shop use. 

Many of the dies shown were made by him personally, others 
were made from sketches, and under his personal supervision, 
while others were made and used in various pressrooms of which 
he had an intimate knowledge ; and the rest, especially those on 
bicycle tools, are from the columns of the American Machinist 
and other papers devoted to mechanics. 

Certain parts of these articles have been published in the 
columns of the American Machinist; also a few pages can be 
found in the catalogue of the Mossberg & Granville Manuf g Co., 
which were contributed by the writer. 

Trusting this work may prove a help to the great army of 
die-makers now pushing their way to the front, is the wish of 

THE AUTHOR. 

Providence, R. I., 

September 30, 1897. 



Dies and Die Making. 



THE ORIGIN OF DIES. 

The origin of dies is, without doubt, very obscure. Perhaps 
the frontispiece in Mr. Oberlin Smith's excellent work on '■•The 
Press Working of Metals " will give as good a likeness of the 
original die-maker as we shall ever find. A search in some of 
the best libraries and museums has failed to reveal any informa- 
tion that is at all ancient, and that can be relied upon. The 
samples of old coins that have been handed down to us, show 
that the art of die-sinking was known to the ancient Greeks at 
least eight hundred years before the Christian era, but they do 
not show that the use of punches and dies was equally well 
known. 

The first record of punches and dies used in a machine or 
press (having guides or ways to ensure the punch entering the 
die correctly) is in the fifteenth century, when they were used 
in the manufacture of hinges, by a German locksmith. Later on, 
in the sixteenth century, we find them in use both in Germany 
and France; and as early as the year 1796 a patent was granted 
to one u De Vere," of France, for dies for punching and draw- 
ing of sheet metal. 

In 1827, M. Gagalott took out a patent for press and tools 
for drawing up cartridge shells from sheet copper. These were 
nearly the same shape as those in use at the present time, and 
the dies were probably of the same design. 

In the article on "Drawing Presses," on page 22, will be 
found a history of the first drawing press made in this country, 
used for drawing up kitchen utensils, — the facts of which can 
lie vouched for, and were related to the writer by one of the 
workmen employed, Mr. J. L. Kirby, now superintendent of the 
Dover Stamping Co. The facts relating to the use of drop 
presses for "striking up" sheet metal were also obtained from 
thi' same source. 

The author would be pleased to learn any facts relating to 
the use of dies prior to that time, and would like to hear from 
any of his readers on this subject. 



10 Dies and Die Making. 

PROPER SELECTION OF STEEL FOR DIES. 

Steel intended for punches and dies should in all cases when 
possible be ordered directly from the mill, giving all the informa- 
tion possible as to the use to which it is to be put, and the class 
of work it is intended to punch. The steel should be annealed 
at the mill, as the extra cost is more than offset by the ease which 
it is worked, and the certainty with which it can be hardened. 

Much of the trouble now experienced with die steel could be 
avoided by this method, except that caused by improper heating 
by the smith in hardening. Steel for dies should be free from 
seams and flaws and of even color, not to be high in carbon 
(from .007 to .009 per cent, is a good proportion) and capable 
of being hardened without shrinking or changing its shape to any 
great extent, except in the case of drawing dies, where this fault 
is a desirable one, as the die can be (when worn) reduced to size 
by being re-hardened, thus increasing the amount of work the die 
will perform. 

When you have once found a grade of steel that you know to 
be suited to your work, k 'stick to it" (and don't be induced by a 
smart agent with a box of cigars to give him an order even if he 
claims that he has a brand that will not shrink or change in the 
least, and would stand any degree of heat without injury). If 
you find that it is impossible to get any one grade that will till 
the bill for all kinds of dies, mark each brand so that you or 
your men can tell at a glance what kind of stock it is. A good 
way is to paint a stripe the whole length of the bar, and a differ- 
ent color for each make or brand of stock. The stripe the whole 
length of the bar, indicates the make no matter how short the 
piece may be, and as shellac is usually the most abundant paint in 
the shop, use red, black, and white shellac, and but three grades 
of steel. 

For drop-press work for cold dropping, use a steel that is a 
little high in carbon, and give the dies plenty of stock to avoid 
breakage. For very large dies for drop-press work and where they 
are to be used on thin stock, as tin or sheet iron, a die made of a steel 
easting and case hardened will give good results. Where a large 
amount of labor is necessary to produce the die as in the case of 
watch or clock dies, get the best steel that can be found, as it is a 
poor policy to try and use a poor grade of steel for intricate work. 



Dies and Die Making. 11 

MAKING A PLAIN PUNCH AND DIE. 

Having found a brand of steel that is suitable for the work to 

be punched it should first be machined to the proper size and 
shape, which will depend on the class of work it is to do, and the 
style of die-shoe it is intended to he used in. A good way, and one 
that is adapted to a large class of work, is to bevel the edge of the 
bar to an angle of 10 degrees, leaving the ends as they come from 
the forge or saw. To get out these blanks cheaply, cut the steel 
up into two or three lengths, plane up and bevel the edges to the 
proper angle, and then saw off as wanted to the required lengths. 

This style of die can he held by a key or set screws, whichever 
the practice may he. 

The upper surface of the die should he finished on the surface 
grinder if there is one, or by hand with the use of the file and 
scraper, as the time thus spent is saved in the laying out of the 
die. and the work can he laid out better, and more distinctly than 
on the rough machined surface of the blank. 

The surface of the die is now covered with what the die-maker 
calls k * blueing," hut what is really sulphate of copper, and is made 
by dissolving sulphate of copper or blue vitriol in water (a pro- 
portion of ten parts of water and one of crystals makes a good 
solution), this leaves a thin deposit of copper on the surface of 
the steel, leaving an excellent surface for laving out the die. The 
outline of the piece to he punched should now be traced on the 
upper surface of the die: care should he taken in laying out to avoid 
waste of metal, also that the grain of the stock to he punched runs 
in the proper direction so that it can he easily prepared for punch- 
ing. A margin equal to the thickness of the metal to he punched 
must be allowed between the blanks, and if the stock is 1 1 ( ." or 
less, it is better to increase this proportion. 

The die being neatly laid out from either drawing or template, 
all round corners should be drilled with a drill of the proper dia- 
meter to leave the corner the shape, and then reamed with a reamer 
of the proper taper to give the die the clearance wanted; the rest 
of the stock is now removed by drilling. Every die-maker has a 
way of his own for this part of the work; one will drill so that the 
holes will cut into each other and thus avoid broaching, while the 
next man will drill holes so that there will he :i \," or more between 



12 



Dies and Die Making. 





Fiff. 2. 



them, and then cut out the stock with a flat, square- 
ended tool called a "broach." This is the best and 
quickest way. The bulk of the stock being removed, 
if there is a die-sinker in the shop, the die can be par- 
tially finished on it, and by using a mill of the proper 
taper, the necessary clearance can 
be given; this will vary from i to 
3°. Excessive clearance is given 
when it is essential that the blank 
should drop from the die before the 
next piece is punched. 
The die being worked out as far as the machine will do it, is 
now finished with the file, using the die square (Fig. 2) to give it 
the proper clearance, and if the shape is an intricate one that must 
be closely followed, a template made of thin sheet metal and 
soldered to the end of a bent wire will be found a help in making 
the required shape. 

If the die is for a press room using a large number of dies, it 
should be marked with a shelf and rack number, so that it can be 
quickly found by the die-setter ; the die is now ready to harden. 

The die being finished, the blank for the punch, which, if the 
shape of the die demands it. 
should be a forged one (hut 
if possible, should be cut from 
the annealed bar), should be 
machined on both ends, and one 
end finished, then clamped 
firmly on to the face of the 
die, using a die clamp (Fig. 
3); now scribe through the 
die, and mark the outline of 
the punch on the finished end 
of the blank. This should be 
nicely marked with a centre 
punch. The stock can best be 
removed by the use of a mill- 
ing machine, as a base or 
shoulder, of the same shape 
but of a larger area, can be 




Dies and Die Making. 



13 



more easily left with this tool than the 
shaper. The object of this base is to 
give the punch better support, and 
increase the length of time it can be 
used. 

The stock having been removed 
close to the lines, the punch should 
be placed over the die and then forced 
into it Jg", thus giving a "witness" 
mark to hie to. This is called "shear- 
ing in," and is the method 
usually employed in this coun- 
try. The reverse of this opera- 
tion, known as the "French'' 
way, consists of finishing and 
hardening the punch, and 
then broaching out the die 
with it. The results obtained 
by this practice are not as 
accurate as those by the first 
process described, as the die will change to a greater extent 
in hardening, than the punch, and it is not so easily finished. The 
punch should now be carefully filed to the lines formed by the 
"shearing in" process, and if the work requires it, should he 
hardened; hut should in all cases he left softer than the die. 
When possible, the punch and shank should he in one piece, but 
if not, care should he taken to see that it has a good bearing on 
the punch hack, and is held firmly to it. 

Fig. 4 showes a plain die for blanking out a tool that all are 
familiar with. No stripper is shown, but the two holes at the back 
are intended to hold one on. 

The letter "C" denotes the brand of steel that the die is 
made of, and is very useful in keeping a record of the results 
obtained from the different brands of steel. 




Fiff. 4. 



14 Dies and Die Making. 



BLANKING DIES. 

A set of blanking dies consist of a male die, or punch, and 
the lower or female die ; they are made in almost every form and 
size for cutting out flat blanks from steel, iron, paper, mica, etc. 

Usually both punch and die are hardened and tempered ; some- 
times the punch is left soft, and as it gets worn, is set out and 
refitted by being forced or shoved into the die ; sometimes it is 
best to reverse this operation, as in punching paper, playing cards, 
etc., and harden the punch and leave the die soft. 

A shear is usually given to the punch or die, determined by 
the work it has to do ; when it is intended to use the blanks, or 
pieces punched out, the shear should be given to the die, as less 
distortion is given to the metal by this method, but where the hole 
is the object sought, — as in rivet holes in boiler plates, etc., — the 
shear should be given to the punch. 

Cutting or blanking dies are usually held in a shoe or die 
holder, or if a large die, it is fastened to the bed of the press 
direct, but as a rule the fewer pieces intervening between the 
press and the die the better results will be obtained. 

Very large blanking dies are usually made in one of two ways ; 
either as rings set in a cast-iron holder, or by welding the rings 
directly on to a wrought-iron holder or die plate ; the latter method 
is the best in making plain dies, but cannot be used in compound 
dies. The welding of the steel rings together, and then on to the 
wrought-iron plate, calls for good work on the part of the smith. 
Some of the finest work of this kind we have ever seen is done at 
the works of the E. W. Bliss Co., at Brooklyn, N. Y., large steel 
rings, both round and square, being welded to wrought-iron beds 
or die-plates, and the joints so perfect they could scarcely be 
detected. 

In the former method the rings are first welded and then 
turned, hardened, and ground true in the universal grinder, then 
set in a groove turned in the holder as shown in the sketch 
(Fig. 9, page 20), and held there by being bolted from the back 
of the holder. The distortion of these rings, caused by long use 
of the die, is something that is hard to account for, the lower or 



Dies and Die Making. 15 

die ring often being dished to such an extent as to close in the 
top or cutting edge of the die so much that it is necessary to grind 
it out and refit it to the punch, a ring of 20" diameter, and made 
of 2" square steel, being out over |" on the bottom or lower edge; 
this is caused, it is thought, by the strain left in the ring in hard- 
ening, and which is released by the grinding of the die. 

In making dies for hot work (as the blanking out of nuts and 
other thick work from red-hot metal), a die made of chilled cast- 
iron, with a good clearance, will give good results, as the temper 
is not affected by the heat of the stock punched, the punch being 
made of steel and titting the die loosely (in very thick stock a 
difference of J^" or more in the diameter of the punch and die is 
not too much), and if a nice job is wanted, the work can be shaved, 
or re-punched, as it is called, by forcing it through a second die 
that is a trifle smaller than the first, leaving a true and smooth 
surface. 

In the re-punching of brass and copper, the use of butter-milk 
as a lubricant will give a better result than any oil or soap Mater 
that we have yet found. Dies for re-punching or finishing work 
are not in general use to the extent that they would be if the 
saving that could be effected by this method were well known. 
Many jobs now performed on the milling machine could be re- 
punched, and 1 letter results obtained at less cost than by the 
former method. 

The power required to blank out a piece of metal depends 
largely on the shape of the blank and the number of cutting 
inches in the die; a long, narrow blank requiring more power than 
a round blank of the same area, the shear of the dies being equal. 
If the work will admit of the face of the punch 1 icing slightly 
rounding, less pressure will be required than with a flat-ended 
punch. 

The first thing to be considered to determine whether a punch 
and die should be used to produce work, is the number of pieces 
wanted. If it is standard work, and the demand is 100 or more 
per week, it is both desirable and economical to have a die made, 
for after the die is once made the work can be produced at a very 
low cost. Oftentimes when a large number of pieces are wanted, 
and a power feed is used, the cost will not exceed two cents per 
1,000 blanks. 



16 



Dies and Die Making. 



BENDING DIES. 




Bending sheet-iron or wire can be done to good advantage in 
either drop or power presses, and a few styles of dies suitable for 
this class of work are shown. The one shown in Fig. 5 is in- 
tended for bending any ordinary thickness of sheet metal or wire 
where a square bend is wanted. It is known as a Universal 
bending die. and will be found very useful, from the fact that it 
will do a very large range of bent work. The different steps are 
for 1 (ending an angle near the end of a strip, and for making 
bends of different depths. 

The second die shown is for bending up a loop in a wire shown 
by the small sample at one side of the die. It will be found very 
effective in making looped wire for armature connections, switch- 
board work or other places where a looped wire is required. The 
wire is placed in the die by hand, against a stop, — not shown in 
the illustration, — and as the punch descends, the loop is bent 
down by the same, and as the end of the punch strikes the bottom 
of the die the spring gives way and allows the side benders, — to 



Dies and Die Making. 



COflPOUND BENDING DIE. 




Fie. 6. 



be forced in by the inclined wedges (formed on the lower end of 
the two pins,) — to force the wire solidly against the center punch, 
and as the punch rises the side bending jaws are carried back by 
the wire itself which is removed from the punch by hand, the end 
of the punch being ball-shaped to facilitate the removal of the 
same. The loop just formed acts as a guide for forming the next 
loop, the wire being moved along and the loop held against the 
stop (not shown) while the second loop is being formed; and then 
this operation is repeated indefinitely, according to the length of 
wire desired. This is a very successful style of die, as it does in 
one stroke of the press what would otherwise require a second 
operation. 

The third die, Fig. 7, is for bending the piece on the right- 
hand side of the punch. This is blanked out by a previous 
operation placed in the die by hand, and is bent as shown by the 
finished piece on the left-hand side, which does not show it so 
clearly as it should. The two sides of the blank are bent down, 
and the long one on the right is curved around the punch shown. 



18 



Dies and Die Making. 




Fisc. 7. 



and the ring on the end is twisted around to a right angle to the 
rest of the arm. 

The punch is made from a single block of steel which is planed 
up to tit the press, and then machined out as shown in the cut. 
The twister, which is for turning the ring at right angles to the 
rest of the arm, is counter-bored in and held in place by the 
quarter-inch pin driven into the side, and which is held up by the 
spiral spring seen at the upper right-hand corner of the sketch. 

The die is self-contained as is used in an ordinary single-stroke 
press, and requires no extra attachments to enable it to do the 
work. This same principle can be used in many cases, and the 
1 (ending performed in one operation which would otherwise re- 
quire two or more strokes of the press. 



Dies and Die Making. 



19 



COMPOUND DIES. 




Fis. 8. 



A compound die is, as 
the word indicates, a com- 
pound of a die and punch, 
or to speak more clearly, 
the upper half consists of a 
punch set inside of a die, 
and the lower or bottom 
half of a die set into a 
punch, the punch cutting 
the outside diameter of the 
blank, which is at the same 
time pierced in the centre 
by the upper punch, thus 
finishing a blank at one 
stroke of the press, that would otherwise require two or more 
operations if done on plain dies. 

The work from a die of this class is far better than when done 
by the ordinary gang or double die, as the accuracy of the work 
depends on the care with which the die is made, and not on the 
skill of the operator. They are especially efficient when used on 
mica, paper and other substances that do not admit of the use of 
a gang die: also on work that must be practically perfect, for 
example — the blanks for watch and clock movements, sheet-iron 
disks for electric armatures, and other work where the relation of 
the centre or other holes to the outside diameter must be perfect. 
The invention of the compound die, and the adaptation of the 
same to the finer grades of work, as watch and clock movements, 
is due to A. L. Dennison, of Waltham, Mass., and was used in 
connection with the sub press, also designed by him. 

Though originally designed for the smallest work, the idea 
has been extended, and it is now used lor dies of the largest size, 
for both light and heavy work. The die shown in Fig. 8 is a 



20 



Dies and Die Making. 




Fie. 9. 



washer die, intended for cutting washers out of .scrap mica, the 
centre punch (A) piercing the hole at the same time the outside 
is being cut by the die, and as a perfect washer is punched out of 
scrap mica at each stroke of the press, its advantages can be 
easily seen. 

The above illustration shows a method of making plain com- 
pound dies for electrical work that will be found very serviceable 
— dies that can be easily made and kept in order. The upper and 
lower cutting rings are forged up and welded, finished in a lathe, 
and ground to size after being hardened. 

The centre punches are made from solid stock in the same 
manner. Both inside and outside strippers are shown, for remov- 
ing the scrap, and are made from machine steel ; the whole die is 
seated into a cast-iron holder. The illustration shows the 
construction of the die so plainly that further description is 
unnecessary. 



Dies and Die Making. 21 



Fig;. 10. 



Fig. 10 is a sketch of the largest compound round die of 
which we have any knowledge, but should any of the readers of 
this book know to the contrary, we should be pleased to hear 
from them. 

There are many dies containing more cutting surface, but in 
actual diameter, we think this exceeds them; it is used for 
blanking sheet-iron disks for the armatures of large electric 
railway generators for street car service: 

Outside diameter . . . . . . . 45 in. 

Inside " 25 in. 

Weight of Punch 1,200 lbs. 

Weight of die 1,100 lbs. 

Cutting surface 290 in. 

In work where the stock is too heavy to admit of the use of 
springs, the press is fitted with a "knock-out" for the lower and 
upper dies, thus doing away with the springs. The pressure 
required to strip a complicated piece of work from the dies is 
very great; and a test made with a die of l<i" diameter, and 
containing 274" of cutting edge, the force required was between 
3,500 and 4.000 lbs.; thickness of stock. .025" sheet iron. 



22 Dies and Die Making. 



DRAWING PRESSES. 

The use of presses for shaping or "drawing up" sheet metal 
is of comparatively recent origin, and although it was not 
original with the French mechanics, it Mas improved, perfected 
and first put to practical use by them, for while evidence can lie 
found of their being in use in Germany in the sixteenth century, 
there are no details that are worth publishing. 

In 1796 a patent was granted to one DeVere, for a press and 
dies for working sheet metal, and in 1827 M. Gazalott took out a 
patent for a cartridge shell drawn up from sheet copper. These 
were nearly the same shape as those in use at the present time, 
and probably the drawing tools were of the same design as those 
now made. 

In the early '60's, two French workmen came to this country 
bringing with them a wooden model of a drawing press. This 
had been made from drawings taken from a press upon which they 
had been employed in France. This wooden press anus secreted 
in a barn near the city of Wilmington, Del., and was finally 
shown to Henry Marchand, who was a brother-in-law of one 
of the men. Marchand, who was a mechanic of fine ability, saw 
at once the value of the invention, and, as he afterward expressed 
it, "would rather have seen the press than had five hundred 
dollars in gold." 

Mr. Marchand at once started to raise funds to build and 
operate the press, and after many delays a company was formed, 
known as the Higgins & Marchand Go. Work was commenced 
on the press at Philadelphia, but Mr. Marchand soon discovered 
that they were secretly copying each part of the press as fast as 
it was made, and the parts of the half finished press were taken 
to Wilmington, and finished at what was afterward known as the 
Higgins & Marchand shop. It was set up in one corner of the 
shop, which was boarded in, and only three men were allowed in 
the room, to one of whom, Mr. J. L. Kirby, now Superintendent of 
the Dover Stamping Go., Cambridge, Mass., the author is indebted 
for this information. The press was a single action cam press, 
the cam being used to force the drawing punch through the die, 
the blank holder beino- held down to the work with a 3,000 lb. 



Dies and Die Making. 23 

weight which was worked by a long 16' lever, extending' through 
the wall. The first piece of work drawn up was a wash basin, 
made from a 14" blank, and was probably the first piece of drawn 
work ever made in America. 

The second press was a great improvement over the first, the 
long lever and weight being discarded, and side cams for the blank 
holder substituted in its place. This press is still in use in the 
simps of the Dover Stamping Co. The blank holder has been 
removed, and the top hamper taken off; the press is now used for 
a few special jobs. No punching was done on the press, as it was 
used for drawing only. It had been in constant operation for 
nearly forty years, when it was displaced by one of E. W. Bliss's 
latest presses, about a year ago. This is an authentic, if not an 
exhaustive, account of the origin of the drawing press in this 
country. 

There is one thing about drawing up a long shell out of a 
round blank that is a puzzle. That is, if you draw up a long 
tube 1" in diameter, out of, say, a 12" round blank, where does 
the edge of the blank go? It is 36" around that piece of metal 
when you start to work on it, and only 3" when you get through. 
Where has the 33" of edge gone? "It is.'" as one of the boys said 
one day, "-all crumpled up and drawn out into the shell." 



DRAWING DIES. 

Drawing dies may he divided into three kinds, plain draw- 
ing, or ••push through" dies, solid bottoms or "knock-out," and 
combination dies. These last named may lie subdivided into 
single, double or triple action, or the number of operations may 
be extended as far as the ingenuity of the die-maker will carry 
him. In the private press room of the Plume & Atwood shops 
at Waterbury, Conn., seven distinct operations are performed on 
one piece of work before it leaves the press, the stock being fed 
in automatically, and the work carried from one set of dies to the 
next in the same manner. Such presses are only possible when 
the work is to he done in large quantities, and the cost of the 
press and dies is very great, three of the presses spoken of costing 
nearly $30,000.00. 



24 



Dies and Die Making. 



PLAIN DRAWING DIES. 




Pull Off 



Fisr. 11 



In sketch Fig. 11, we show a plain "push through" drawing 
punch and die, the blank being punched out to fit the "set edge" 
and then "drawn up," or rather, it is pushed through the die by 
the punch, and as the punch rises, the work is stripped from the 
punch by the " pull off," which is made very sharp for that pur- 
pose. A "draw" of about one-quarter to one-half of a degree is 
given the die, making it that much larger on the upper side or 
face, and the upper edge is rounded over and left very smooth, 
and as hard as fire and water will make it. "Don't draw a draw- 
ing die." The lower end of the punch is rounded and left in the 
same shape ; often the die will work better if the finish is 
changed from a circular to a lateral polish. The diameter of 
the punch is equal to that of the die, minus double the thickness 
of the stock to be drawn. A die of this kind can only be used 
on shallow work, or in redrawing or reducing the diameter of the 
work that has been previously drawn up ; if used on deep drawing- 
it will pucker or crimp around the edge. To avoid this, we must 
have a blank holder to hold the stock firmly while it is being 
drawn. 



Dies and Die Making 



*j.) 



SINGLE ACTION COMBINATION DIES. 




Fig. 12. 



Fig. 12 shows a single-action cutting and drawing die, better 
known as a single-action combination die. A combination die is, 
as the name indicates, a combination of a drawing die and cutting 
die in one; it punches the blank, and at the same stroke of the 
press, draws it up into a cup or shell. The die shown is intended 
to be used in an ordinary single-stroke power press, and will draw 
up work not over one or two inches deep. 



26 



Dies and Die Making, 



SOLID BOTTOM DIES. 




Fiff. 13. 



The die shown in Fig. 13 is the same general design as the 
previous one, except that it is a ••push hack" or "solid bottom" 
die, and is used for taper and flared work that could not he done in 
a " push through " die, such as thimbles, taper ferules and lamp 
burner parts. The action is the same as the "push through"' style, 
except that the work is pushed back by a -follow plate" worked 
by a "knock-out" attached to the press, and so arranged, that, as 
the drawing punch rises from the work, the "knock-out" strikes 
the plate pin and pushes the work from the die, and is removed 
either by a swinging arm, or by the use of an inclined press. 



Dies and Die Making. 



27 



DOUBLE ACTION DIES. 







■ 1 








i 


L 


\ 




A 


I 


— 


' Lj 


r 


jj j 



C|D r f 1 -, X G 



— E 



J 



Fie;. H. 



A double-action die is a modification of a single-action die, to 

be used in a double stroke press; it can be used on work that is 
too deep for single-action dies. The one shown in the sketch, 
Pig. 14, is known as a "push through" die. It is somewhat like 
the single-action die, except that the shell is cut by the punch 
( B), and is carried to the drawing die (D), and the lower sur- 
face of the die acting as a blank holder is held there while the 
drawing- punch (A ) forces it through the drawing die. and as the 
punch withdraws, the shell is removed by the lower edge of the 
die. which is ground very sharp for that purpose, and is known 
as the "pull off." The drawing die is held in place by the 
cutting die being clamped upon it by the ring (G-). 

This style of die has this advantage; the cutting and drawing 
dies are independent of each other, and can be changed for a 
longer or shorter shell, or either die can be repaired or replaced 
without chansjiiiL!' the other. 



28 



Dies and Die Making. 



TRIPLE ACTION DIES. 




Fig-. 15. 



Triple-action dies are intended to punch, draw and .stamp the 
work at the same stroke of the press. The construction is the 
same as the double action, except that the die block (E) is cut 
away to allow the stamping die (F) to be set in place, and the 
shell is carried down to the stamping die and "struck up" between 
that and the matrix formed on the end of the drawing punch; as 
the punch rises, the work is stripped from the punch by the "pull 
on ," and is removed from the dies by the use of an inclined press, 
or by a swinging arm attached to, and operated by the press, that 
catches the work as it falls from the punch. 

This style of die is largely used on blacking box covers, lard 
pail lids, or other work where a stamped or embossed cover is 
wanted. A die of tins class should always be used in an arched 
press, as the strain of the stamping process is very severe on the 
"open back" style press, and is apt to crack the body of the press. 
In making a drawing die, use a steel that is high in carbon, and 
if it shrinks a little in hardening so much the better. There is on 
the market at least one grade of steel which will stand three suc- 
cessive hardenings. and will shrink each time so that the die as it- 
wears out, can be "shrunk up" and then ground out to size again. 



Dies and Die Making. 29 

Various modifications of a drawing die arc necessary in order 

to successfully draw up the different metals. Zinc works better 
when the soap suds, or whatever lubricant may be employed, is 
used hot as possible, as that metal works much better at a heat of 
about 125°. 

In -drawing up very delicate work where the nature of the 
metal is such that the die is inclined to clog, or as the press hand 
calls it "copper up," the use of butter milk will he found very 
effective. 

In drawing very thick work the drawing die can be made bell 
mouthed, as the thickness of the metal will reduce the tendency 
to crimp or pucker. The same method of making the die is 
followed when it is desired to draw a shell that is very short in 
proportion to its diameter. 

The possibilities of what can be done by this method of form- 
ing up sheet metal are almost unlimited, and the press of the future 
as shown by the frontispiece, is not an exaggeration of what will 
lie performed at no distant day, as trunks, wheelbarrows, sinks 
and the copper boiler for hot water service are e very-day pro- 
ductions at the present time. 

The great secret of drawing up work is to have good metal, 
and to properly adjust the blank holder, so as to hold the metal 
just hard enough to prevent it from puckering. In drawing up 
metal, always keep one thing in mind, that is, that metal has some 
of the properties of water, and it will flow where it can go the 
easiest. A grade of steel which will harden good, a little 
knowledge of tool making, and a good deal of experience are 
what is needed to make a o-ood drawing die. 



30 



Dies and Die Making. 



DROP PRESS DRAWING DIES. 

The use of drop presses for 
stamping and forming work is very 
ancient. The first information of 
the drop press being used in 
this country was in 1838, 
when the Dover Stamp- 
ing Co m p a n y w a s 
founded by Mr. Horace 
Whitney, at 
Dover, N. H. 
They were used 
for making tin- 
ware, which 
previous to that time had 
been formed up by hand. 
In 1847, Mr. Whitney 
started manufacturing, 
using a number of tools 
of this kind, some of 
which are still in ex- 
istence at the works of 
the Dover Stamping 

Company, now at Cam- 
Fig. 16. 1 J" 1 

bridgeport, Mass. 
These presses are used where the nature of the work demands 
that it shall receive a blow or force to enable it to retain the shape 
given it by the dies, and which cannot he readily given in a power 
press. They are also used for drawing up shells or cups in place 
of the ordinary press, as the work can he done cheaper than by the 
use of the power press, unless furnished with a roll or automatic 
iced. In the die shown. Fig. 16, the blank is held in place by the 
"set edge," and as the punch comes down, the blank holder 
strikes the work and prevents it from crimping while the punch 
compressing the rubber spring draws the blank down into the die. 
and give it the shape desired. Drop dies are also used for strik- 
ing up work that has been previously drawn up in the drawing 
press: also the bending and forming of both sheet metal and 
wire. For important improvement in this class of tools see page 88. 




Dies and Die Making 



31 




JACK DIES. 




FACE 

Fio\ 18. 



The illustrations show two methods of holding the upper die. 
or as it is sometimes known in shop language, the "jack" or "pick- 
up" die: the die being held by a taper shank which fits into the 
hammer of the drop, or by the dovetail which is keyed into the slot. 

The former method is best adapted to hammers of 100 lbs. 
weight or less, and the latter to large dies or pick-ups. The under 
or face side of the jack is scored across with two or more slots at 
right angles to each other, and the face hardened. The lower die 
is made and finished, and the blank for the tipper die or force is 
heated to a cherry red, and placed under the hammer which 
is brought down with all the force that can be applied, driving the 
hot metal both into the slots in the pick-up, and into the lower 
die, forming the punch or force, and at the same operation attach- 
ing it to the hammer. 

This seems to he a crude method of holding what is often a 
nice piece of work, but careful search proves it to be the one 
universally practiced in all sections of this country. 



32 



Dies and Die Making. 



ARflATURE DIES. 



^™%^ 





2/z/umi# 



Fiff. 1!>. 



The phenomenal growth of the electrical industry in the last 
few years, and especially in the use of notched or slotted sheet- 
iron disks for the armature cores, has stimulated the invention and 
use of compound dies of large diameter and complicated designs. 

The modern armature resembles somewhat a gear that is built 
up of thin sheet-iron plates or disks, usually about .010" to .040" 
thick, and from 12" to 100" diameter. These are, in the best 
of armatures, punched from sheet iron, with centre holes, keyway 
and the teeth, or, as they are called, "the winding slots," at one 



\ j i 










G 


1 




. 






D 


1 
















D 








F 




1 ill A 




F 





R! 



Fig. 20. 



U 



ij 



Dies and Die Making. 33 

stroke of the press; the smaller ones in a complete disk, the larger 
sizes in as large sections as it is possihle to procure the iron ; and 
as some of the styles are very intricate, the ingenuity of the die- 
maker has been taxed to the utmost to produce what is wanted. 

The method first adopted was to blank out the plain sheets, 
and then put in the centre hole and keyway with a separate die. 
The sheets were assembled on the shaft and turned to size on the 
lathe ; the slots for the winding coils were then cut in a milling 
machine, and the core was ready to wind. It was soon found 
that the contact of the sheets caused by the milling process was 
detremental to the electrical efficiency of the armature, and the 
use of a dial-feed press was adopted for punching the slots before 
the sheets were assembled on the shaft. This gave 1 letter results, 
except that irregularities of the punched sheets required a good 
deal of tilling to correct them, the effect of which was the same as 
that caused by the milling process, except to a less extent. This 
led to the development of compound dies that would punch sheets 
so perfectly that they could be assembled on the shaft or spider, 
and the armature wound without any further labor expended on it. 

Fig. 20 shows one of the latest designs of these dies, adapted 
tor use in an E. W. Bliss, No. 95 press, which comes nearer meet- 
ing the requirements called for, than any other in the market. 
This press is fitted with a "knock-out" capable of exerting a 
force of 5,000 lbs., thus obviating the use of springs in the lower 
stripper. The upper stripper is also worked by a stationary 
"knock-out" attached to the body of the press. 

This die is a. sectional one, is set into a steel casting, instead 
of cast iron, as is generally done. The rings "A," "B"and 
"C" are of tool steel hardened and ground to size, and the rest 
of the rings are left soil. 

These dies are invariably sub-pressed, as the utility of the die 
is greatly increased by this process. 

A die of this kind, well made, and run at a speed of 55 
revolutions per minute, operated by two men, will produce 4.000 
to 6,000 20" sheets per daj of ten hours, using 10,000 to 15.000 
lbs. of iron. 

The cost of these dies varies from slOO.OO to $800.00 each. 
according to design of the armature, and they weigh from 1.0(H) 
to 2,000 lbs. each. 



34 



Dies and Die Making. 



ARMATURE DIES. 




Fig. 21. 



The above illustration shows a die for a small armature blank 
for fan motor work; also a punching from the same. The die is 
a compound one, sub-pressed by the use of four pins, two of which 
are shown in the illustration. 

The difficulties of making the die were such that, at first, it 
was deemed impracticable ; but the urgent necessity of getting out 
the work, which was being done by the use of a dial feed press, 
made it advisable to make a trial of this method of punching. 

The lower die was made precisely as shown by the punched 
blank, of a piece of Styrian steel, which was carefully annealed, 
turned to the required shape, drilled for the thirty-seven holes, 
and then slotted on a milling machine and left soft. 

The upper punch, or, as it really is, the die, was made in two 
pieces; the inner punch hardened and ground and forced into 
place in the upper casting, and the outer cutting die made in the 
same manner and seated in a recess machined out concentric with 
the centre punch. 

The knock-outs or strippers were made, the lower one in two 
pieces, and then held together by the outer ring shown, which 
was forced on, holding them firmly together. This knock-out was 
fitted with thirty-seven pins of the same diameter as the holes in 
the disk, so arranged that as the punch was withdrawn the scrap 



Dies and Die Making. 



35 



was forced from the holes by the action of the spring shown in 
the illustration. 

The upper knock-out, for removing the blank itself, was 
actuated by a knock-out attached to the body of the press, and so 
arranged that when the press reached the highest point of the 
stroke it was forced against the plate shown in the centre of the 
upper part of the die. 

The die was a success, and was run continuously, day and 
night, producing several million sheets before being replaced by a. 
new one. 



NEEDLE DIES. 



■^^-iOO-i I Ham. 



The illustration, Fig. 22, shows 
a small die and holder which is 
largely used in needle factories for 
punching the eyes of sewing-ma- 
chine needles, and is intended to 
be used in a press adapted to that 
class of work. The die is a sectional 
one, made in three pieces, the cen- 
tre one projecting up above the 
surface of the two sides and into 
the groove of the needle, thus sup- 
porting the latter while it is being 
punched. This centre piece is cut 
out with a U-shaped slot, the width 
of the slot being equal to the length 

of the eve of the needle, the two blocks forming the sides of the 
die and the whole held firmly together by a set-screw not shown. 

The press is so arranged that the needle is first clamped (not 
shown) and then punched, the speed of the punch at the moment 
it enters the die being very slow. The punches are made of 
Stubb's wiic about .080 diameter, milled down to a diameter equal 
to the length of the punch, and are then hardened and the sides 
are ground in a special grinder. A punch of .004 diameter is 
used on the finest needles, and a punch of .008 to .010 is a com- 
mon size in every-day use. 




Fijr. 22. 



36 



Dies and Die Making. 



FLUID PUNCHES. 




Fie. 23. 



The well-known fact that water cannot be compressed to any 
great extent, has led to the use of fluid punches for shaping and 
expanding work that would otherwise be impossible to do in a 
press, and may be used as a medium for conveying force, as in the 
case of a hydraulic press, or the fluid may be applied directly to 
the work with or without the use of a packing ring. 

The illustration shows a die designed for shaping ice pitchers, 
and intended for use in a heavy drop press, the die being made in 
two parts. 

The pitcher is placed in the die, which is then closed and placed 
in the clamp ring, force being applied by the plunger swelling out 
the work to the shape of the die. A special preparation of wax 
is often used in place of water or oil in connection with dies of 



Dies and Die Making. 



37 



this kind. In presses used for the manufacture of hats, 800 lbs. 
pressure to the square inch is applied to the Avork. The lower die 
which is of cast iron or spelter, is placed on the bed of the press 
and then brought up to the water cylinder and locked. The water 
is then turned on and a bag of thin rubber is expanded, filling 
the entire inside of the hat and allowing the whole pressure of the 
water to come upon the material, remaining some ten seconds, 
when it is removed the press unlocked and the hat removed. When 
the water is applied directly to the work, it is usually done in a 
drop press as the pressure can be applied very quickly and but 
little packing is required. This method of press work is also 
followed in the manufacture of silverware, or where it is desired 
to swell the centre of the work to a diameter larger than the end 
of the same. 

RIVETING DIES. 

Wheiv a large amount of riveting has 
to be done, the work can be produced 
better on a riveting machine arranged to 
spread the head of the rivet by a revolving 
heading tool than it can on a press, but 
ofttimes it is desirable to do a limited 
amount on a press, and the die shown will 
be found a very good one for the purpose. 
The illustration is so plain that it explains 
itself. It is intended for bicycle chain 
work, the upper and lower dies are made 
convex, and the rivets headed by rapid 
reciprocating blows of the same. A stiff 
short stroke press is necessary for riveting. 

When a large number of holes are re- 
quired to be riveted, and the work is of a 
nature that it can be done at one blow, the 
drop press will be found preferable. In a 
shop engaged in the manufacture of 
wrenches, seven to ten rivets are headed 
at a single blow of the drop. On page 47 
will be found an illustration of a die for imitation rivets. \vl 
as it is not really a, riveting operation, is shown separately, 
it may not be confounded with the one just described. 





Fi£. 24. 



UCll, 

that 



38 



Dies and Die Making. 



GANG DIES. 




Fig. 25. 



Fig. 25 shows a die intended for punching out a diamond 
shaped piece pierced with four round and four triangular holes, 
and a square hole in the centre. The die being a small one is 
made in one piece of steel. 

Laying out of work of this kind required skill on the part 
of the die-maker. Proper allowance must he made for the '■'creep- 
ing' 1 of the stock, also for the margin between the pieces punched. 
The large punch should be fitted with a centre pin projecting into 
the square hole which has been previously punched by the centre 
gang punch; the pin, however, is not shown in the cut. 

When the die is a large one, and especially if the holes or 
work is round, it is preferable to make the dies separately, and 
then set them into a cast-iron holder. 

Gang dies are also used very extensively when a large number 
of blanks of the same kind are wanted, also in punching rivet 
holes in tank or boiler work, and making perforations in gas or 



Dies and Die Making. 



39 



lamp burners, as high as 1,500 holes often being pierced at one 
stroke of the press. In work of this kind it will be found ad- 
visable to have the stripper fit the punches very tightly, so that it 
will act as a guide, and support the punches while they are enter- 
ing the stock. A good illustration of a stripper of this kind is 
found on page 64. 

SECTIONAL DIES. 






on 



• • 



m 



~i 



• •_ 

« • 

• * 



Dies of large sizes or of a 
difficult shape, can usually be 
made to better advantage in sec- 
tions, for in the former class the 
dies can be separately made and 
tempered, and set in place in 
the holder, thus forming a com- 
plete die, requiring less stock. 
Should a part be spoiled in mak- 
ing or hardening, it can be easily 
replaced; whereas, in a solid die, 
the whole would be spoiled. 

Fig. 26 shows a. method of 
making a small compound die in 
sections that was adopted be- 
cause it was found impossible to 
produce work that would meet 
the requirements of the case, 
with the best solid die that could 
be made. The pieces wanted 
were simply flat blanks of .014" 
thin sheet-iron 2" X 4" in size, 
with S" centre hole. A limit of 
.002" was all that could be given 
on the dimensions. A large num- 
ber of these was wanted, requir- 
ing the use of dies that must not 
vary over .002" from each other. 
After many trials with solid 
dies, which failed on account of the contraction caused by harden- 
ing, also by the changing of the die as it wore out, on account of the 



L 


imp 








1 o 






■.;::.:■ 








::>:%%'-v>; :: .. -■ - : .. ' ;>./■•:; ':-:-. A ?' 





o 



Punching 

from Die 



Fie. 26. 



40 



Dies and Die Making. 



Z."7\_ O. 




Fig. 27. 



clearance given, a die was made like the sketch, the sides and ends 
of the die were made in separate pieces, hardened and ground to 
size, and held in place by the shrink ring, the centre punch "B" 
perforating the blank at the same time that the outside is cut. No 
clearance was given to the die, as the work was removed by a 
spring stripper, thus rendering the clearance unnecessary, and en- 
abling the die to hold its size until worn out. This style of die 
gave such good satisfaction that it was used exclusively for this 
class of work, and the extra cost of the die was more than off- 
set by the decreased cost of the work produced. 

Fig. 27 illustrates a large punch and die that was made sec- 
tional, from the fact that it was impossible to get steel of the 
proper size for the die, as soon as wanted. The punch and die 
were both made in sections, and ground to a perfect fit after being 
hardened. The dotted lines show the manner in which the joint 
was made. The results obtained from the die, in cutting qualities 
and shape, were better than had it been made solid. The size of 
the die was about 18" X 20", and the stock punched was thin 
sheet iron. The labor cost of the work, though somewhat more 
than it would have been for a solid die, was more than offset by 
the saving in the amount of stock used. The die was set in a 
cast-iron holder having eight lugs which were fitted with set- 
screws, forcing it firmly together and making a solid die. 



Dies and Die Making. 



41 





1 






















/ 


No. J 


















\ 








—/ 




No. 2 




No. 3 



No. 4 




No. 5 



No. 6 



Figr. 28. 



Dies for armature sheets are almost invariably made in sec- 
tions, so arranged that each piece may be taken out and replaced 
without disturbing the rest of the die. Fig. 28 shows some of 
the shapes made in this style. 

No. 1 — A square sheet-iron disk with centre hole, also cut 
across the side. 

No. 2 — A washer with a section cut out. 

No. 3 — A transformer sheet. 

No. 4 — A clock wheel blank. 

No. 5 and 6 — Armature sheets, punched at one stroke of the 
press, the dies made in sections. 



42 Dies and Die Making. 



BURNISHING DIES. 







Fig. 29. 



When a nicely finished piece of punched work is wanted, the 
piece is first blanked ont a little larger than the finished size and 
then pushed through a die that is slightly tapered, that is, it is 
made larger at the top or upper side. The cutting edge of the 
die is a little smaller than the blank so that a shaving is taken off 
around the edge, and then it is forced through the die, which is 
made very smooth on the upper part. This leaves a finely finished 
surface on the edge, and is used on work that would otherwise 
require milling or buffing, such as bicycle chain links, and the 
large and small sprockets, for finishing operations. The die shown 
is intended for finishing bicycle links by the use of a dial feed. 
The centre hole is punched at the same time the link is blanked, 
and is centered on the burnishing die by the use of a pin that 
enters the hole and holds the links firmly while passing through 
the die. 

It is important that the inside of the die is made smooth, 
well finished after being hardened. This style of die will, when 
made and properly used, save a large amount of milling and buff- 
ing, and will produce work that is uniformly accurate. 



Dies and Die Making. 



43 



WASHER DIES. 




cur 



Fig. 30. 



These illustrations show three distinct methods of producing 
washers, each of which has its advantages according to the mate- 
rial used. 

The compound washer die in Fig. 30 is used for thin work, 
and where an accurate cutting die is wanted, for punching paper, 
mica, thin sheet-iron or hrass. The illustration shows so plainly 
the method of making the die that little explanation is necessary. 
The spring stripper is used on the lower die, as it is called — 
which is in reality a punch — and a spring shedder or knock-out for 
ejecting the blank from the upper die. The advantage of a die 
of this kind is that the material is pressed Hat and smooth by the 
spring stripper before being cut, thus giving a more perfect washei 
than can be made by any other method. 



44 



Dies and Die Making. 



REVERSED WASHER DIE. 




'UTLET FDR 
SCR'AF 




KNOCK HEP P/N5 



Figr. 31. 



The die shown in Fig. 31 is intended for thick washers, the 
punch being made with an outlet through the shank of the same 
for the scrap from the centre of the washer, the blank remaining 
in the die until it is ejected by the shedder which is actuated by 
a knock-out motion applied to the press. This die can be used for 
washers \" and |" thick, and will produce perfect work even 
when using scrap stock, which is a difficult thing to do when 
using the gang washer die shown on the following page. It is 
especially adapted to collars and ball cups for bicycle work. 



Dies and Die Making. 



45 



GANG WASHER DIE. 




Fig. 32. 

This illustration shows a gang washer die intended for punch- 
ing washers of any description, and is the style ordinarily used. 
It is necessary in using a die of this kind that one edge of the 
stock be straight, in order that in feeding it may be kept firm ly 
against the hack gauge so as to ensure its being properly fed. 

Another method of producing washers may be described, and 
consists of first cutting out the blank with a gang of punches, the 
press being fitted with a roll feed, and punching 25,000 washers 
pci' hour, or from one to two tons per day. These are then put 
through a second operation for piercing holes in the same, the 
press being fitted with two dies which are fed by tubes, the washer 
being carried to the bottom of the tube and deposited under the 
centre of the punch which pierces about 200 washers per minute, 
or about one-half ton per day. 



46 



Dies and Die Making. 



TRIPLE DIES. 




Fig. 33. 



This illustration shows a die intended for slotting the ends of 
tubes or other shell work, and is intended to be used in any 
ordinary power press. 

The dies are held by a hollow stud which fits the inside of the 
tube or shell to be punched, the scrap passing into the cavity 
(A) and dropping through the outlet below, left for that purpose ;. 
the punches being held in the side carriers (B), which are driven 
by the inclined studs (C) secured by the punch holder (D). 

The die is self-contained, and can be removed from the press 
and set in the die rack in the usual manner. The punches are 
straight pieces of steel wire of the proper shape to tit the die, 
and are held in the same manner as shown on page 51, Fig. 39, 
and not by the set-screws as shown in the illustration. 

The advantage of a die of this kind is the reduced cost of 
the work, and the better results obtained, as it is impossible to 
get out imperfect work if the die is properly made and used. 



Dies and Die Making. 



47 



IMITATION RIVET DIES. 




TTT~ffi 




Fig. 34 



The above illustration shows a die for imitation rivets intended 
to he used on thin sheet-iron work, such as hoops for tubs and water 
pails, tinware, attaching hinges to stove ovens, or other work of a 
similar character. 

The advantage of the die is, that no stock is removed from 
the parts to he joined, and no rivets arc required. The punch is 
driven through the double thickness of stock on the first set of 
punches, and then finished on the second set. The only object of 
the second set of punches is to avoid turning the work over, as 
the operation could be performed equally well on a single set. 

It is not really a riveting operation, being more of the nature 
of an eyelet than a rivet, but is described as such from the fact 
that it is often used in place of solid riveting, especially on thin 
work, such as pail hoops, band iron, and in putting handles on 
the cheaper grades of tinware. The operation can he rapidly per- 
formed, and applied to many classes of work not specified. 



48 



Dies and Die Making. 



FOLLOW DIES. 




Fig;. 35. 



Follow dies, so called when two or more operations follow 
each other, that is, the piece is first stamped, pierced and then 
blanked out. Sometimes this order of operation is reversed and 
the piece is stamped and cut off at the same time, the holes having 
been punched at a former stroke of the press. 

The illustration shows a die for making a clip, used for holding 
armature binding wires, and will be recognized by many of our 
readers. The stock is first stripped the proper width and fed into 
the dies by hand and the finished clip is knocked off the die in the 
same manner. 

The same idea can be used for a large variety of work. Slots 
or holes can be punched in either or both ends of the blank, and 
any style of bend can be made that does not exceed an angle of 
ninety degrees, and where the depth of the bend is not more than 
three-eighths or one-half inch. 

The difficulty of making a long bend is that the cutting punch 
must do the work before the bending die comes into use, and must 
necessarily pass down into the die whatever the depth of the bend 
may be. The work should lie entirely cut off by the punch just 
at the moment it is struck by the bending die, otherwise it will lie 
apt to be moved from its' proper place, resulting in imperfect work. 



Dies and Die Making. 



49 



ARMATURE LEAD DIE. 




Fig. 36. 



The illustration, Fig. 36, shows a die intended for cutting and 
forming a half-round piece, or, as it is called, a lead, which was 
formerly in great demand for armature work. The stock is fed 
from the left of the die, covering the small die shown in the bottom 
holder, and as the upper die comes down the stock is trimmed on 
both edges and bent to the shape shown, as the press reaches the 
full length of the stroke. 

The piece shown at the right of the die is a gauge, and is sup- 
ported on pointed screws, held up by the springs in the centre, so 
that as the upper knives come down it is depressed out of the May, 
but rises to its place again as soon as the punch returns. 

This idea can be used for a large class of die work, and requires 
no attachments of any kind applied to the press. 



50 



Dies and Die Making 



TUBE BENDING DIES. 




Fig. 37. 

The second sketch is for the 
dies are the same ; the method 
obviate the necessity of cutting 
first die. 

These sketches are 
taken from the col- 
umns of the American 
Machinist, and not 
having seen the same in 
practical operation, it is 
imp o s s i b 1 e to state 
w h e t h e r satisfaction 
equal to that obtained 
by the use of two 
sets of dies can be had 
by their use. 



The illustrations show 
two methods of forming 
up a tube at one stroke 
of the press, doing the 
work with a single oper- 
ation. 

The first of these, 
shown in Fig. 37, is pub- 
lished by permission of 
Mr. C. H. Hardinge of 
Chicago, who gives the 
origin of the same as 
follows: That he ob- 
tained the same from a 
die-maker of his ac- 
quaintance who learned 
the trick from a tramp- 
ing journeyman, 
same purpose ; the action of the 
of construction being changed to 
out the deep slot shown in the 




Fig. 38. 



Dies and Die Making. 



51 



HOLDING SHALL PUNCHES. 




Fiff. 39. 



Small punches always give more or less trouble from breaking 
and then sticking in the punch back or holder. The method 
shown in Fig. 39 is designed to overcome this difficulty. The 
punches which are straight pieces of Stubbs' steel wire, are cut off 
and headed on the upper end and hardened. The chuck, which 
is made with a removable collar, is split in the centre, one side of 
which can be removed by loosening the set screw. The ease with 
which this can be done makes it unnecessary to send the job out 
of the press room. The punches can be made and kept in stock 
and renewed, and the punch replaced without the necessity of 
removing the die from the press. 

Small punches are broken, not in punching the work, but in 
the withdrawal of the same. The cross section of the stripper in 
the centre of the cut shows how it should be made so as to prevent 
this trouble, the stripper being machined off on each side so as to 
have a 1 tearing on the work to be punched, close up to the punch. 
When possible, the stripper should be bolted on to both sides of 
the die. 

Out of many methods and plans devised for holding punches, 
this one gives the best satisfaction, on account of the ease of 
making and removing the punches. 



52 



Dies and Die Making. 



SUB PRESS DIES. 




Fig. 40. 



A sub press, is, as the name indicates, a press set under a 
press, and was designed by Mr. A. L. Dennison of Waltham, Mass., 
for the making of watch movements, and at first consisted of two 
pins acting as guides for the moving part of the sub press, which 
being quite a distance from the punch, served to make it enter the 
die correctly. 

A very interesting article on the origin of the sub press, as 
well as the illustration and description of the first die thus made, 
by Mr. Dennison, can be found in the America)), Machinist of 



Dies and Die Making 



53 




Fig, 41. 



March 5th, 1891, and will repay anyone for looking- it up who is 
interested in this subject. 

For regular sub-pressed die work, the form shown in Figs. 40 
and 41 will be found a good style to use. The inside of the 
casting, shown in cross section, is made tapering, and bored out 
true with the plunger, and a heavy nut is fitted to the top, as 
shown in the illustration, so that the babbitt with which the 
sub press is filled is kept tight by screwing down the nut and 
forcing the babbitt into the taper and against the plunger. 

in making a die for the sub press, it is made and fitted in the 
usual manner and set in its place. The punch is then carefully 



54 Dies and Die Making. 

set, and the space around the plunger is filled with the best quality 
of babbitt metal. The plunger has three parallel grooves milled 
to prevent the liabilty of its turning in use, and the upper half or 
arch of the press is shouldered on to the base and then held to the 
same by screws, shown in the cross section Fig. 41. The plunger 
is driven by the slot shown at the top, and is attached loosely to 
the gate of the press. No dependence whatever is placed on the 
ways of the press, but the stiffer the press in which the die is run 
the better the results obtained, as it is considered good practice 
that the punch should never enter the die, but should come down 
and punch out the work without the edges coming in contact. 

The illustration on page 34, shows how a die may be fitted up 
when the height of the die space in the press will not admit of a 
regular sub-press casting being used. The punch and die are made 
in the regular way, and after being finished the punch is entered 
into the die about yL" and is kept in position by parallels being 
placed between the two. They are firmly clamped together, and 
while thus clamped the holes are drilled, reamed and the four 
pins, only two of which are shown in the illustration (which are 
hardened and ground), are fitted in the holes in the bed of the 
lower die, then the clamps and the parallels are removed and the 
die is ready for use. 

These pins insure the punch entering the die perfectly, and do 
not depend on the ways of the press or the skill of the operator in 
setting the same. 

The advantage of having a die sub pressed, especially if it is a 
complicated one, can hardly be over estimated, as a die which 
before being sub pressed would cut but two to four thousand 
blanks with the ways of the press as carefully adjusted as it was 
possible cut twelve to forty thousand after it had been thus 
arranged, and the work was of a superior quality. 



Dies and Die Making. 



SOFT PUNCHES AND DIES. 

When punching thin slock, sheet iron, or soft metal such as 
copper, brass, etc., a soft punch will give equally good results to a 
hardened one, for when worn it can he taken out and upset 
and then "sheared in" by putting it in the press and forcing it 
through the die. When the blank or the piece punched out is the 
object sought, as in playing cards or cards for photograph work, 
the reverse of this plan is followed. The punch is made straight, 
hardened, the die is left soft as it gets worn, is set in with a pean 
of the hammer and the punch forced through it, thus practically 
making a new die, also keeping it exact to the size wanted for 
the work. Where the stock is very thin, machine steel will he 
found equal if not better than tool steel, and the operation of up- 
setting the punch will harden it, so that it will become very tough. 

A punch of this kind well fitted will run off eight to sixteen 
thousand blanks from soft metal, and with less injury to the die 
than though a hard punch was used. For forming up sheet tin or 
other kitchen ware, cast-iron dies and a lead force are often used; 
the die being set in the press and a punch shank is secured in the 
hammer and then the melted lead poured around the shank, filling 
the die and forming a lead force. This is an ancient practice and 
is seldom followed in an up-to-date shop. 

In exceptional cases the punch and dies can both he left soft 
to good advantage. This is particularly the case when the work 
to be punched is very thin or soft metal, or an intricate pattern 
that would be liable to crack or change in hardening; or if they 
are to be used on paper, which if cut in thin sheets is a very 
easy material to work, hut when large numbers are punched at 
the same time it is one of the most obstinate of substances, on 
account of the toughness of the same. 

A most interesting article on the punching of paper or fibre, 
which is practically the same thing, appeared some months ago in 
the columns of the American Machinist, by Mr. Oberlin Smith, 
who has made some most interesting tests on the power and tools 
required. Although not classed as soft punches, fluid punches 
are often used in expanding or distending work described on 
page 3(3. 



56 



Dies and Die Making. 



A SET OF DIES. 

The illustration shows a set of 
dies designed for blanking, forming 
and piercing a set of springs and 
holders intended for holding car- 
tridges in rapid tiring army rifles. 

The second and third dies are 
plain gang dies designed for blank- 
ing and piercing the clip. 

The large die shown at the right 
is for bending up one of the clips at 
one operation, and is constructed on 
the same principle as the one shown 
on page 46., the side benders com- 
pleting the springs at one stroke of 
the press. 

The fourth and fifth dies, and the 
three punches over them, are for 
bending the second spring, three 
operations being required. 

The fourth and last dies are for 
bending and piercing the springs, 
one of which requires three opera- 
tions, and the other but one, the 
whole being shown to illustrate the 
number of tools often required for 
very small articles. 

An attempt has been made by 
the photograper to illustrate the 
work done, by placing a spring in 
front of each die, with, however, 
but partial success. 



Fig. 42. 



Dies and Die Making. 



57 



CHUCK FOR MAKING PUNCHES. 




Fig. 43. 



The advantage of having a chuck for turning out punches from 
solid stock, capable of taking a heavy chip without springing and 
still run perfectly true, is well known. 

The illustration shown, represents one which will till all wants 
in that direction. It is simple, and can he made in the shop, no 
special tools being required. The boys in the shop used to call it 
a "Pratt & Whitney" chuck, because a part of the tool, at least, 
is similar to one which is largely used by that firm, but the split 
cone is, I think, original. The base or internal portion of the 
chuck is screwed on to the mandrel of the lathe in the usual man- 
ner, and the split rone, which is provided with bushings to accom- 
modate all sizes of steel, from one inch down, is gripped by the 
outer shell, which is worked by a spanner similar to the ordinary 
chuck. 

For those who have much of this class of work to do, they will 
be well repaid for the trouble and expense required to make them, 
for made in the shop, the cost will not exceed $15.00 each. If 
some enterprising firm would take hold of the matter, they proba- 
bly could be produced for half this sum. 



58 



Dies and Die Making. 



SPRING DIES. 




Fig. 44. 



The half-tones show a 
combination punch and die 
for cutting and bending a 
sheet metal spring, the 
stock being fed in with a 
roll feed, and then removed 
by the use of an inclined 
press, shown on the oppo- 
site page. Any length of 
spring, up to the length of 
the die, is made by simply 
changing the length of 
feed. The stock is cut off 
and fed by gravity to the bending die, and after being bent, is 
removed in the same manner, the bending up of the ends of the 
spring allowing it to pass freely from the die. 

Considerable trouble was experienced in getting the die to 
work nicely, but it was accomplished, finally, by the use of kero- 
sene as a lubricant on the under die. 

The press shown is what is known as a "Style B" Press, and 
the illustration is loaned by 
the courtesy of the Moss- 
berg & Granville Mfg. Co., 
by whom the dies shown 
were made. The same 
style of press is largely 
used on can, pail, and other 
tinware, in connection 
with a single action die 
shown on page 25. Fig. 45. 




Dies and Die Making. 



59 



INCLINED POWER PRESS 




Fi£. I*!. 

The advantage of a press of this kind is that single action 
combination dies, shown on page 25, can be used either in 
connection with a roll feed or without, and the work removed 
without any special attachment; the operation of the die being 
that, as the punch rises, the work is raised to the top of the die 
and removed by gravity. The expense of the die is greater, hut a 
larger amount of work can be accomplished than with the " Push 
Through" double action die shown on page 27. 

The greatest disadvantage of the inclined press is the incon- 
venient position of the press for die setting. This is avoided in the 
style shown, which can he instantly changed to the upright position. 



60 Dies and Die Making. 



DIE HOLDERS AND BOLSTERS. 




Fig. 47. 

Die holders and bolsters are used for holding dies to the bed 
of the press, the holder often being used to support some part of 
the die that would otherwise be unable to stand the strain of 
punching. They are usually made of cast-iron, except for heavy 
work, when steel casting will be found preferable, as steel does 
not crack under any strain, and will stand more abuse than the 
cast-iron holder. 

The holder shown in Fig. 47 is a good style, and is adapted to 
a large variety of work. It can be set either way in the press, and 
with either keys or set screws for holding the dies. If screws are 
used, the dies should be made of standard width, as 2", 4" and 6", 
and thus avoid a large variety of holders. Dies for drop presses 
are usually held in a round block, as they can be more readily set 
in the drop, and are held by four or six screws, known as '■'poppets," 
as shown in Fig. 82 on page 84. This manner of holding a die 
will give good results, and it is suitable for all drop press work, 
except drop forgings, for which the dovetail slot in both hammer 
and anvil will be found preferable. 

The four holders shown in the large cut, Fig. 48, are intended 
for taking a uniform range of dies, and the shoe is so designed 
that it may be removed and replaced by simply loosening the bolt, 
as it is not necessary to remove the nut, the slot being so designed 
that the holders may be pulled toward, and then sideways, and 
thus removed from the press. 

The bolster plate, shown in the last illustration, is intended to 
be placed on the bed of the press, and the die holder fastened by 
the use of two cap screws or stud bolts, which are not shown in 
the illustration. The die holder and bolster are used as shown on 
the press on page 59. 



Dies and Die Making. 



til 




fed 



Fig. 48. 




Fig. 49. 




Fig. 50. 



62 



Dies and Dip: Making. 



A GANG PRESS. 




Fig. 51. 



The illustration on the opposite page, Fig. 52, shows a gang of 
foot presses ; Fig. 51, one of the dies used in the same, and intended 
for notching and mitering skylight bars. They are made with 
three, four or six presses on one table, and intended to be used in 
consecutive order, each press being fitted with dies for performing 
a certain operation on the bar. 

The die and punch, which are shown with the stripper removed, 
are so arranged that the back of the die acts as a guide and pre- 
vents the punches from sheering and being forced away from the 
die when cutting. 

The press is made by the West Manufacturing Company of 
Buffalo, N. Y., through whose courtesy the illustration of the 
same is shown. 



Dies and Die Ma k inc. 



63 



A GANG PRESS. 




Fig. 52. 



64 



Dies and Die Making. 



CAM STRIPPERS. 




Fig. 53. 

Figs. 53 and 54 show a die having a cam-actuated stripper, also 
press specially adapted to the use of the same, illustrations of 
which arc loaned through the courtesy of the E. W. Bliss Co. 

The great advantage of a stripper of this kind is less liability 
of breaking the punches, and the thicker stock that can be punched 
on account of the decreased length of punches that can be used, 
which are made very short, and are held in a punch back. The 
stripper plate is fitted with bushings, which guide the punches and 
support them while piercing the metal. 

Fig. 53 shows the details of the die and punches, the punches 
being held in the punch block which is fitted with a backing plate 
of hardened steel; the stripper plate is attached to four vertical 
rods which receive their motion from two cams on the main shaft. 
When the stripper is up, a free space is left between punch and 
die, enabling the operator to manipulate his work quickly and 
accurately. The stripper comes down on the blank, straightening 
it and clamping it tight before the punches enter, and holds it 
while the punching and stripping is done, and the work comes out 
perfectly straight and true. As the stripper moves up and down 
with the punches, they may be made shorter than a stationary 
stripper would permit, and the punches used are therefore more 
rigid and lasting. This also enables the punching of smaller holes 
in proportion to the thickness of the stock, the stripper acting as a 
guide for the punches up to the moment when they enter the 
metal. 



Dies and Die Making. 



65 



CAH=ACTUATED STRIPPER PRESS. 




Fig;. 54. 



The press shown has a 6" crank shaft, weighs about 15,000 
pounds, and is geared 7i to 1, and is one <>t' the latest productions 
of the E. \Y. Bliss Co. 



6<o 



Dies and Die Making. 



U. S. STANDARD PUNCHES AND DIES. 




Fig. 55. 

The following illustrations are loaned through the the courtesy 
of Mr. I. P. Richards, the well known inventor of the only stand- 
ard for round punches and dies, and the best method for holding 
the same. The shank which is shown in Fig. 57 is fitted to the press, 
and the punches are held in place by the coupling. The punches 
being a standard length, can be easily renewed when worn, or ex- 
changed for a larger or smaller size without disturbing the adjust- 
ment of the press. They are made in all sizes 
from h" to4" diameter, and adapted to almosl 
all classes of round work, but more especially 
for punching out holes for boiler, tank, and 
other work which is secured by riveting. 

The punch shown in Fig. 58 is ground 
shearing thus reducing the power required 
for operating the same. These punches are 
furnished by the inventor, Mr. Richards, at 
a less cost than they can be made by consum- 
ers, although the patent on the same having 
expired, they are open to the public, and are 
extensively copied by other manufacturers, 
often, we are sorry to say, without giving Mr. 
Richards the credit which is due for 
the invention and his efforts to intro- 
duce and maintain a standard punch. 

While we have no data of the power 
required to operate these punches, we 
have reason to believe the statement 
that 40% is saved by their use. 





Dies and Die Making. 



<;t 




Fis;. 57. 




Fie. 58. 



68 



Dies and Die Making. 



PUNCHES AND DIES FOR NUT WORK. 




Fis;. 59. 







Fig. 60. 



Fig. 61. 



Fi«r. 62. 



Fig. 63. 



In the manufacture of nuts it is customary to make each opera- 
tion a separate one; that is, the bar is first cut up into short 
lengths, and then the holes punched the entire length of the bar; 
the nut is then roughly blanked out, and put through, or rather 
under, a crowning punch which presses the corners, and leaves 
the circle on the top, shown in Fig. 62. The nut is then put 
through one, two, or three shaving dies, each of which takes off a 
thin shaving, and leaves the side of the nut very smooth. The 
greater the number of operations the nut passes through, the better 
the finish obtained. 

Various attempts have been made to reduce the number of 
operations required in this work, and thus produce a nut at a less 
cost. These attempts have met with more or less success. Per- 
haps the nearest approach in this direction has been made by the 
Port Chester Nut Co., who punch a blank and shave a nut at each 
stroke of the press. This is a patented process, and for that 
reason is not shown here. 

The Figs. 59, 60, 61, 62 and 63 show the first, second, third, 
fourth and fifth processes. The curvature of the bar is caused by 
the first punching, as the metal invariably stretches more on the 
under side ; this however is but of little consequence as it does 
not show in the finished nut. 



Dies and Die Making. 69 



FORGING BICYCLE SPROCKETS. 




Fig. 64. 

Fig. 64 illustrates a method of making bicycle sprockets that 
is both better and cheaper than that usually followed, and one 
that is not in general use. It is the invention of Mr. L. B. 
Munger, — who is well known for his improved methods of manu- 
facturing bicycle parts, — and has been copied to some extent by 
his competitors. 

The sprocket is blanked out in the usual manner, and the cross 
area of the stock that is left to form the spoke is carefully calcu- 
lated, so that after the sprocket has been through the forging die, 
no fin is left around the edges of either spoke or hub. This calls 
for good judgment as well as accurate measurement on the part 
of the die-maker, as it has proved a failure in several cases where 
an attempt has been made to adopt Mr. Hunger's method. 

The tail shown on the blank is intended to be grasped in the 
tongs while heating, and in placing the blank upon the forging 
dies, and cut off after that operation. 

This same method is followed by Mi'. M linger in all kinds of 
forgings the work being first punched out to the proper size, 
leaving the required amount of stock necessary to till the die, and 
is then forged, leaving little or no lin, and avoiding the trimming 
process after the work has been forged. 

This method has been jealously guarded by Mr. Munger, and 
is here published for the first time with his full permission. 



70 



Dies and Die Making. 



A GROUP OF ARMATURE PUNCHINGS. 




Illustration Fig. 65 shows a group of armature punchings, all 
of which are blanked out by means of compound dies, the largest 
of the group being 36" diameter, and the smallest one, which is 
shown in the centre, li" diameter; the others being respectively 
4". 6£" ami 20" diameter. 

A detailed description of the dies for producing this work is 
given on page 32. The methods of constructing the dies are so 
varied that it is impossible to give a plan which will fit all styles 
of armature sheets. Plans or sketches for dies for any work of 
this character will lie furnished on request. 



Dies and Die Making. 



71 



A GROUP OF SMALL PUNCHINGS. 



r —^i 




Ml'! 

12 IN. 

Fie. 66. 



The above illustration shows a large variety of different 
articles which art- produced wholly, or in part, by press work. 

The four corner illustrations will be recognized by those 
interested in bicycle manufacture, being punchings of sprocket 
wheels made by four of the leading manufacturers. The figures 
14, 15, 19, 21, 31 and 35, arc also parts for bicycles: and numbers 
'■'>-< 42, 44 and 47 represent the pieces used in the construction of 
the well-kaown bicycle whistle. 



72 Dies and Die Making. 

SPEED OF PRESSES. 

The speed at which a press can be operated depends upon the 
nature and thickness of the stock being punched, the quality of 
the steel of which the tools are made, and the material used for 
lubricating the same. In punching a soft material, such as paper, 
cloth or very thin sheet metal, a speed of 200 to 350 revolutions per 
minute is practical, as the fiber of the metal does not require to 
be broken, as is the case when operating on thick or hard material. 

The old-fashioned rule that a punch will penetrate metal equal 
in thickness to the diameter of itself, is fast being exploded, as it 
is a well known fact that a i" punch can be put through a 2" bar 
of iron, provided the tools are properly made, and a speed of not 
over one stroke in two and one-half minutes be given to the same ; 
breaking the punch being the result of an increase of this speed. 

In ordinary punching sheet metal, .014" to .04" thick, 125 to 
150 revolutions per minute has been found as high a speed as 
it is practical to run ; in blanking out large sheet-iron armature 
disks, .025" thick, and 20" diameter, more work is produced at 60 
revolutions than at 90, as the dies will stand up to the work 
and run off a larger number of sheets without being ground, than 
when used at higher speed. 

The speed of drawing punches depends largely on the work done, 
and the material used for the same, as a slow speed Avill often 
enable work to be produced that would rupture at a high speed. 
On large and deep shells, a speed of two to four revolutions is 
often necessary, while small and shallow work will stand a speed 
of 150 to 200 strokes per minute. 

The stroke of the press is an important factor which must be 
taken into consideration when estimating the speed at which work 
may be punched, the idea being that the tools must have time to 
break or rupture the grain of the metal, and this can be facilitated 
by giving the proper amount of clearance to the punch, as well as 
the usual clearance to the die ; also care being taken when punch- 
ing a thick metal that the punch and die do not fit too closely. 
Probably more trouble is caused by this one defect in tool making 
than any other. It is hard to convince a good die-maker that the 
punch and die must not fit nicely when used on thick work ; often 
a difference of -X-" to -X-" should be given on work f" in thickness 

a 1 16 & 



Dies and Die Making. 73 

or over. On thin sheet metal the tools must lit nicely in order to 
produce the work without burr, and the speed of the same can be 
greatly increased; 90,000 to 100,000 per day being the usual out- 
put of a press running at 200 revolution per minute, the stock 
being 1 fed with either roll or ratchet feed. 



DIE SETTING. 

Setting punches and dies in the press is often done without 
due regard for the tools, — that they are properly set and adjusted 
for the work they have to do. From a mistaken idea of economy, 
this work is often put into the hands of an operator who has little 
idea of the value of the tools which he is adjusting, and to whom 
any accident caused by improper setting is a small matter. 

To set a punch and die in the press, remove the belt from the 
wheel, unless the press is provided, — as all presses should be, — 
with a countershaft. Place the die and holder, (into which the 
die can be keyed to better advantage on the bench), on the bolster 
plate, and enter the punch carefully by hand; now bring the gate 
or slide of the press down until the bottom of the slide strikes the 
shoulder of the the punch and prevents it from being moved out 
of the die; next ease up slightly on the slide, so that the punch, 
die and holder can be moved along by hand into their proper places 
in the press. The punch, if secured in the head block or chuck of the 
press, is pushed to the left hand side of the dovetailed slot in the 
slide, and the key driven in. The bolt or stud holding down the 
die-holder should now be slightly tightened, and a few raps with 
the hammer be given to the die; this causes it to find its proper 
place on the bolster: the holder is now secured to the bolster plate, 
and the punch withdrawn from the die and then entered again, to 
be sure that the operation of setting has been properly performed. 

No specified distance can be given as to the distance the punch 
should enter the die. In sub-press dies for watch work, the punch 
should come to the surface of the die and enter the least possible 
amount; while in rough crude dies used tor thick sheet iron or 
boilerplates, the removal of the scrap or the piece punched out will 
be greatly facilitated if the punch enter |" or more. 

The above method will not meet with the approval of many. 



74 



Dies and Die Making. 



but a large experience in different methods of die setting has led to 
the description just given. 

There is one good rule which, if followed, would practically 
prevent the accidents now so common in large press rooms, and 
that is: never allow the hand or fingers to be placed under the 
punch while the press is in motion. Many of the accidents which 
occur arc caused by gross carelessness on the part of the operator 
who is induced to take the chances of accidents because of the 
larger amount of work which can be produced. 



BROACHING. 

Although not usually classed with punches 
and dies, the operation of broaching is analagous 
with punching, and for that reason is properly 
entitled to description here. The broach is 
really a punch, the cored or drilled hole in the 
work broached forming a die for the same. It 
is used for finishing holes which may lie either 
punched, cored or drilled in brass, iron or steel, 
and which may be round, square or any other 
desired shape. The operation is best performed 
in a press designed for the purpose, having an 
adjustable stroke of 1" to 12". The broach 
shown is intended for finishing a cored hole, 
and is 2 A" X h" rectangular section, about 8" in 
length. The teeth being very coarse on the 
lower end, are intended for taking out the bulk 
of the stock, until the centre of the broach is 
reached, when they are sheared in opposite direc- 
tions, thus breaking the chip off, and then the 
teeth decrease in size until the upper end of the 
"ig. (37. broach is reached, when the same is left perfectly 

straight for about 2", forming a sizer, keeping 
the finished hole a standard size. The broach is best driven when 
operated on by a V block secured in the press in the same manner 
that the punch is usually held, and as the plunger comes down, the 
broach will find its own centre with less liability of breaking or 
making an imperfect hole. Broaching of almost any length can be 



Dies ani> Die Making. 75 

done in a press having a short stroke, by using a successive number 
of blocks, the broach being inserted in the hole, and driven down 
the full stroke of the press. A block of the same thickness as the 
stroke of the press is then inserted, and the operation can be re- 
peated until the desired length of drive is obtained. The results 
obtained are not equal to a continuous stroke broaching press, as 
the stopping of the broach when partly through the work, gives 
the metal an opportunity to settle into the teeth of the broach, 
thus increasing the liability of breakage. 

There are on the market several machines designed expressly 
for this work, several of which perform the operation by pulling 
the broach through the hole, which is an improvement over the 
method just described, hut as it does not come under the jurisdic- 
tion of this work, the description of this machine is omitted here. 



Dies and Die Making. 



REVOLUTION COUNTERS FOR PRESS USE. 




Fig. 68. 



The use of a revolution counter or indicator for keeping- 
account of the work produced by a press, is preferable to the 
ordinary manner of weighing up or trusting to the intelligence of 
the operator to determine the amount of work done. This fact 
has led it to be adopted by several of the largest press rooms in 
the country, and with satisfactory results. 

The above illustration shows a style which is adapted to all 
makes of presses, as it can be connected either directly to the shaft 
itself, or to the centre, or can be located in front, on the upper 
part of the press, and then connected by a lever from the slide, 
and will give an accurate record of the revolutions made. It is 
simple, having no springs or gears, and can be furnished with 
either four, five or six dials. The five figure indicator shown in 
the illustration will count up to 99,999, and then repeat auto- 
matically. A dial can be set to zero, or the counter can be had 
without the thumbscrews for re-setting. 

In using the counter in connection with gang punches, that is, 
in work that requires one are more strokes of the press to properly 
start the strip of metal used in feeding, there is a loss of six to 
nine per cent, from the number actually indicated. This fact 
being thoroughly understood, the proper amount of work can be 
produced, making the necessary allowance for the false strokes. 



Dies and Die Making. 



BALL CHUCK. 




Fig. 69. 



The illustration Fig. (39 shows a chuck for bench use, which 
is adapted for "working out" punches and dies or any work 
which can he done more conveniently by placing it at an angle, so 
as to use a hammer and chisel to good advantage. The chuck 
was originally designed for and is usually used indie sinking, but 
the advantages mentioned has led to its use in the die room, and 
once introduced, it will be found to he a good tool. 

A base provided with a cavity of the same radius as the 
bottom of the ball is intended to be used in connection with the 
chuck, and is usually made by coiling up an old belt, and then 
striking the chuck firmly down into the same. The die is held in 
the slot, secured by the two set-screws. 

The advantages obtained from the use of this chuck will be 
appreciated by those who have experienced the difficulties of 
chipping out an odd-shaped die. 



78 



Dies and Die Making. 



FINISHING PRESS WORK. 




Fig. 70. 

Perhaps a few words on finishing punched work may be of 
interest to those who have the good or bad fortune to have charge 
of that kind of work, and the barrel shown is specially adapted 
to work of this kind ; being a modification of the ordinary tumbling 
barrel, so arranged that the incline may be varied, giving a greater 
or less effect on the work as may be wanted. 

All punched work as it comes from the press is in an unfinished 
condition, owing to the soap, oil or other substance which is used 
for lubricating the dies, and the advantage of tumbling cannot be 
over-estimated. Burrs can be removed with practically no ex- 
pense, and work put in a salable condition which would otherwise 
be consigned to the scrap. 

For abrasive materials to be used in tumbling the work, there 
is nothing better than broken emery wheels for rough tumbling or 
taking off heavy burrs, and for finishing light, delicate work, 
leather chips and sawdust will give good results. For polishing 
buttons, of hard rubber or papier riiache, old woolen rags will be 
found to give a high polish without marring the work. 

For tumbling shells which have been drawn, but are to be put 
through a second operation, a solution of strong soap water, either 
hot or cold, will be found to give a good polish and also leave the 
work in good condition for the second drawing. 



Dies and Die Making. 79 



BELTING UP PRESSES. 



To belt up a power press properly, set it in line with the coun- 
tershaft or main shafting, and fasten securely to the floor, taking 
care that it is properly leveled, and that each leg has an equal 
bearing on the floor. The better the foundation, the better results 
will be obtained. Take double the distance from the centre of 
counter or main shaft to centre of crank shaft on the press, and add 
one-half the circumference of both pulley and balance wheel, and 
the result will be the length of belt required. If the press is an in- 
clined one, and it is to be used in an upright position also, set the 
press on an incline and cut the belt to the proper length ; 
then set it upright and set a piece of belt of the proper length to 
be used when the press is in that position. Put on a belt the full 
width of the wheel. Do not put a "1" belt on a 4" balance wheel, 
and then expect the momentum of the wheel to do the rest. Do 
not set the press directly under the main or countershaft when it 
is possible to avoid it. Set it at least 2 ft. away, even if you have 
to sacrifice floor space to do so. Run the belt with the grain side 
next to the pulley. A long belt is preferable to a short one, as the 
adhesion caused by the weight of the licit is more desirable than 
that obtained by tight lacing, and the belt will wear longer and 
give better results. 



80 



Dies and Die Making 



FEEDING PRESSES. 





Fisr. 71. 



press itself. 



Feeding by hand is the oldest and most common 
method of feeding press work, and a few words on 
this subject may be of interest. 

When work is to be punched from short stock, as 
most sheet tin stock comes, or where irregular stock 

is used, an auto- 
matic feed is of 
doubtful utility, 
j for the operation 
of keeping the 
feed supplied is 
certainly as 
troublesome as 
feeding the 
In cases of this kind it is best to feed by hand as a 
skillful operator moves his hands with the press and will produce 
work rapidly, but if the work will admit of it, a power feed should 
be used. 

We describe a few of the many kinds in use : roll, ringer, slide, 
double roll, reel, tube, grip, ratchet and friction dial feeds, com- 
bination feeds and knock-outs. 

When large quantities of the same general class of work are 
wanted, and the stock can be procured in long strips or rolls, fit 
the press with a plain roll feed, Fig. 72, as they are easily applied, 
and can be quickly adjusted and changed from one class of work 
to another. They are made in several styles, to feed from front 
to back, left to right, or the re- 
verse,single or double and with 
ratchet, friction, or "pinch" 
adjustments of rolls. The 
amount that can be fed is usu- 
ally regulated by the diameter 
of the rolls except in special 
cases where a rack and pin- 
ion, giving any amount of feed 
wanted, can be used. Fjo\ 72. 




Diks and Die Making. 81 

A finger feed is an adjustable "finger" fitted to and worked 
by the slide of the press, so adjusted that it is raised at each 
stroke just enough to allow the stock to pass under, and then 
catches in the hole punched by the preceding stroke. It is inex- 
pensive, and is not in the way when not in use. When fitted with 
a power reel to wind up the scrap, it becomes one of the most 
useful feeds known, and can be used equally well on both single 
and double acting presses. 

Tube feeds are used for feeding work that has been previously 
punched out by a plain die. It is best adapted for coining, swag- 
ging, etc. The work is caught in a tube as it falls from the 
blanking die, and is then transferred into a second tube placed on the 
press. An automatic moving slide delivers the lowest piece in 
the tube to the dies at the proper time. This feed is largely used 
on coins, medals, buttons, etc. 

An automatic- slide feed consists of a mechanical hand which 
grips the work and then slides it to the proper place on the dies, 
and is specially adapted to a fragile material, as cardboard, paper, 
etc., and is also one of the most accurate style of feed in use. 

A grip or claw feed is so arranged as to enter the first hole in 
the stock just punched, and then draw it ahead the proper distance 
for the next blank. It is easy to adjust, and can be run at a very 
rapid speed. 

Dial feeds, Fig. 71, are used to hold a blank on which it is 
desired to perform a second operation, as armature blanks, or to 
act as a carrier to present the blank in successive rotation to the 
punch, and in some cases to remove the work after the punch has 
performed its duty. They may be belt, ratchet, or friction driven, 
and may be a smooth disk as used for cartridge work, or fitted 
with sockets to hold and carry the work. 

A combination feed is two or more feeds in one, as they are 
usually adapted for special operations, and can not be changed 
with the same east' as the roll or linger feed. 

Knockouts are fitted to many presses to assist in removing the 
work from the dies. They are applied to either the slide or body of 
the press, and in the latter case arc connected by a pitman to the 
end of the crank shaft, so that as the punch rises from the die. the 
work is forced out. 



82 



Dies and Die Making. 



HARDENING DIES. 




Fi«\ 73 



So much has been said on the subject of hardening steel that 
we are disposed to let it alone, but feeling that a work of this kind 
would not be complete without it, will give the results of our ex- 
perience. For heat we prefer a gas furnace of any good make, 
but this not available, a clean charcoal lire is nearly as good. 

Fill all holes in the die that you do not wish to have a cutting 
edge, such as the stripper holes, with fire clay; use plenty of good 



Dies and Die Making. 83 



hard wood charcoal, heat slowly but steadily to an even red. Dip 
the die entirely below the surface in salt water, for while there are 
baths that are good for special work, steel that will not harden in 
clean salted water is not fit to make a die of, keep it in the water 
until it is entirely cold, then put it on the fire again and warm it 
until the heat is as great as the hand can bear, then cool off and 
polish and draw to a light straw. The object of the second heating 
is to lessen the liability of fire cracking. 

For large dies it is indispensable to have a tank properly 
arranged for cooling the steel quickly. This is best arranged by 
having two rods, fixed across the tank about 10" below the surface 
of the water; the water supply is led down below the surface nearly 
to the bottom of the tank. The end is bent up so that as the die 
is plunged into the tub the valve is opened and a circulation of 
water is created in the tank. This method will prevent the soft 
.spots often met with in hardening. Fig. 73 shows the arrange- 
ment so clearly that no further explanation is required. 



84 



Dies and Die Making. 



AN ANCIENT TRIP HAMMER. 




Although not properly classed as a punch and die, and yet 
clearly the result of the laws of evolution, the above illustrated 
tool is entitled to he represented here ; and shows the trip hammer 
in its most primitive form. It is taken from a German illustra- 
tion, loaned through the kindness of the Bradley Co., of Syracuse, 
N. Y., for insertion here. 

The mode of operating the hammer is clearly shown in the 
illustration, the water-wheel attached to one end of the revolving 
drum carries the collar and dog for raising the hammer. 

The method of keying the lower die in the anvil shown, is 
identical with that practiced at the present time, the force of the 
blow being controlled by the in-flow of water actuated by the 
knotted rope which hangs within easy reach of the smith. The 
swinging seat, however, would not be tolerated with the methods 
of operating the hammers now practiced. 

The exact antiquity of the sketch could not be ascertained, but 
it is not far from the 16th century. 



Dies and Die Making. 



BROWN & SHARPE MFG. CO., Providence, R. I. 

TOOLS FOR DIE WORK. 




Fig. 76. 
Micrometer Calipers. 

Made to measure from h" to 24", and to read to .0001". 



liiiliiiliiiliiiliiiiiiiliiiliiilii 



illll iiilin imIiiiIiiiIiiiImi iMliiiliiil iiihi 



|llll|llll|llll|llll|ll!l| 



© 



25 20 15 10 5 



(D 



Fig. 77. 
Height Gauge. 



86 



Dies and Die Making. 



BROWN & SHARPE MFG. CO., Providence, R. I. 





Fig. 78. 

Vertical Spindle Milling Attachments. 




Fig. 79 Fig. 80. 

High Speed Hilling Attachment and Driving Fixture. 




Fig. 81. 
Universal Vise. 

Attachments used with Brown & Sharpe Universal Milling 
Machine for die work. 



Dies and Die Makixc 



87 



PAWTUCKET MFG. CO., Pawtucket, R. I. 




Fig. 82. 
Press for Blanking, Champering and Trimming Nuts. 



MOSSBERG & GRANVILLE MFG. CO., Providence, R. I. 




Automatic Drop Press. 

Designed for all classes of stamping and bending operations and can be 
operated by inexperienced labor without danger of injury. 

88 



Dies and Die Making. 



89 



MOSSBERG & GRANVILLE MFG. CO., Providence, R. I. 




Single Acting Power Press. 

Fitted with instantaneous clutch and stop motion. Designed 
for all classes of punching operations, and can he fitted with roll, 
finger or dial feeds. 



90 



Dies and Die Making. 



E. W. BLISS CO., Brooklyn, N. Y. 

PRESSES, DIES, SHEARS, DROP HAMMERS, DOUBLE 
SEAHERS, TRinriERS. 




Toggle Drawing Press. 

The toggle drawing press as shown in above cut is used in the manufacture of wash 
bowls, milk and pudding pans, tea kettles bodies and breasts, sauce pans, bucket and pot 
covers, small scoops, cuspidors, coal hod bottoms, trays, dust pans, brass and copper goods. 

This press is fitted with an automatic friction clutch ; it can be stopped and started at 
any point of the stroke, by operating hand lever not shown. 

The toggle movement as applied to this press has greatly increased the durability and 
smoothness of action, insuring a more perfect "dwell" of the blank holder than can be 
maintained in presses of any other design. 



Dees and Die Making. 



91 



E. W. BLISS CO., Brooklyn, N. Y. 

EMBOSSING PRESSES, SHEET METAL WORKING 
MACHINERY, SPECIAL MACHINES. 




Armature Disk Cutting Press. 

The press shown in above cut is specially designed for cutting the outside 
and inside of armature disks simultaneously, insuring exact concentric of 
outside and inside circumference. 

This press is fitted with a positive knockout device. 

The same general style of presses also supplied in larger and smaller 
patterns. 



92 



Dies and Die Making. 



NEW DOTY MFG. CO., Janesville, Wis., U. S. A. 




Above cut represents a combined punches and shears in which 
the knives for fiat and round iron are independent of each other 
and of the punch ; and both sets of knives as well as punch are at 
all times times ready for use without any change. While it is a 
single end, it has all the advantages of a double end machine, and 
is much less expensive. 



Dies and Die Making. 



!•:>, 



E. S. STILES PRESS CO., Watertown, N. Y., U. S. A. 




No. 19 Adjustable Incline Press 



No. 3 Punching Press. 



METAL CUTTING, SHAPING and FORMING TOOLS, PRESSES, 
DIES, DROP HAMMERS and SPECIAL MACHINERY. 



94 



Dies and Die Making. 



WATSON AND STILLMAN, New York, N. Y. 




Hydraulic Open Jaw Die Sinking Press. 



A very small press with short motion, on which small medals 
may be struck without the annoying shock of the drop hammer, 
and is an adaptation of their improved hydraulic punch, strength- 
ened in the jaw to avoid spring. 

The body is steel, and from its method of construction irregu- 
lar dies may be used. The lower lever can, if desired, be made 
self raising by weighting it at the rear. 

Power, 60 to 125 tons pressure. 



Dies and Die Making. 



95 



WATSON AND STILLMAN, New York, N. Y. 




Heavy Hydraulic Die Press. 



Adapted for hubbing up very heavy dies. 



90 



Dies and Die Making. 



HILLES AND JONES, Wilmington, Delaware. 




No. 4 Horizontal Power Press for Very Heavy Work. 



For punching boiler heads, crooked furnace plates, bent, angle or 
tee iron, boiler legs and all close or crooked work. 



Dies and Die Making. 



97 



G. A. CROSBY & CO., 176 So. Clinton St., Chicago, III., U. S. A. 




~ ^Tjn^nE^^sM^-- 



No. 2 Power Punching Press. 

Manufacturers of presses, dies, and designers and builders of 
patent automatic machinery for making cans. Write for catalogue 
and information. 



98 



Dies and Die Making. 



THE WATERBURY FARREL FOUNDRY & MACHINE CO., 

Waterbury, Conn. 




300 Ton Knuckle=Jointed Embossing Press. 

These presses are constructed upon, an improved plan which 
permits a powerful machine to he made in more compact form than 
formerly. The main frame is made very rigid and as short as 
possihle (by allowing the guides for the crosshead to he placed in 
front of the knuckle-joints) thereby reducing the spring or elas- 
ticity of the frame to a minimum. 

A specialty is made of designing and building machinery for 
specific requirements. Some of our standard machines are as 
follows: automatic rivet machines, automatic nut blanking 
machines, thread rolling machines, machinery for making hinges 
and butts from sheet steel and brass, machinery for making shot- 
shell and ball cartridges. Patent hydraulic presses, pumps and 
accumulators. 



FERRICUTE MACHINE CO., Bridgeton, N. J. 




INDEX. 



PAGE 

A Press of the Future Frontispiece 

Armature Dies 32 

Armature Punchings 70 

A Group of Small Punching? .... 71 

Automatic Drop Press S8 

Burnishing Dies 42 

Bending Dies ■ 16 

Blanking Dies 14 

Broaching Tools 74 

Belting up Presses 79 

Ball Chuck 77 

Blanking Press ill 

Chuck for Punch Work 57 

Combination Dies 25 

Cam Stripper • 64 

Compound Dies 19 

Compound Bending Dies 17 

Double Action Dies 27 

Die Shoes 60 

Drop Press Dies 30 

Drawing Presses 22, 90 

Drawing Dies 23 

Embossing Presses 98 

Finishing Press Work 78 

Fluid Punches 36 

Follow Dies 48 

Forging Bicycle Sprockets 69 

Feeding Presses 80 

Gang Dies 38 

Gang Washer Dies 4.") 

Gang Press 62 

Hydraulic Presses 94, 95 

Hardening Dies 82 

Holding Small Punches 51 



PAGE 

Imitation Rivet Dies 47 

Inclined Presses 59 

Jack Dies 31 

Largest Dies 21 

Making a Punch and Die 11 

Milling Attachments for Die Mak- 
ing 86 

Needle Dies 35 

Nut Press 87 

( >rigin of Dies 9 

Power Presses 89, 93, 99 

Punches and Dies for Nut Work. 68 

Plain Drawing Die 21 

Proper Selection of Steel for Dies 10 

Revolution Counters 76 

Reversed Washer Dies 44 

Riveting Dies 37 

Set of Dies, A 56 

Sectional Dies 39 

Spring Dies 58 

Sub-Pressed Dies 52 

Setting Dies 73 

Soft Punches and Dies 55 

Speed of Presses 72 

Standard Punches and Dies 66 

Solid Bottom Dies 26 

Shearing Presses 92 

Triple Dies 46 

Triple Action Dies 28 

Trip Hammer 84 

Tools for Die Work 85 

Tube Dies 50 

Washer Dies 43 



